Composite laminate having an improved cosmetic surface and method of making same

ABSTRACT

A composite laminate includes a plurality of sheets of prepreg stacked one over another, and a scrim layer provided on an exterior surface of the sheets of prepreg. Each prepreg sheet is formed of fibers preimpregnated with resin. The scrim layer and the sheets of prepreg form a composite laminate whereby the scrim layer constitutes an outer, exposed surface of the composite laminate. The scrim layer may be a nonwoven carbon or glass fiber scrim that has absorbed resin from the sheets of prepreg. A method of making a composite laminate includes placing into a mold a scrim and a plurality of sheets of prepreg, with the scrim extending between an exterior surface of the sheets of prepreg and an inner surface of the mold; forming a composite laminate whereby the scrim is adhered to the sheets of prepreg; and removing the composite laminate from the mold. An outer layer of the composite laminate includes the scrim.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a Divisional of U.S. application Ser. No.11/932,244, filed Oct. 31, 2007, the entire disclosure of which isincorporated herein by reference thereto.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to composite laminates, and moreparticularly, the present invention relates to composite laminatesprepared from fiber reinforced resin impregnated materials.

2. Background Art

Many products are formed of plastics because they are light weight andcan be readily shaped and styled. Electrical equipment enclosures, suchas enclosures for computers and portable electronic devices, forexample, are typically formed of plastic materials to make aesthetic,functional housings. Plastic housings for electronic equipment can beboth rigid and lightweight, and can be durable without being bulky.Electronic equipment enclosures also typically provide shielding againstelectromagnetic pollution, such as that which emanates from theelectronic device or exists in the surrounding environment.

Plastic housings for electronic equipment may be prepared from plasticmaterial reinforced with carbon fiber. Carbon fiber reinforced plastic,also referred to as carbon fiber composites, provide a very strong,lightweight material for forming housings for electronic equipment.Carbon fiber composites may be formed by layering sheets of carbon fibermaterial into a mold that is the shape of the desired product. The moldmay then be filled with a thermosetting resin (e.g., an epoxy resinprior to being cured) and the resin cured to thermoset the resin (e.g.,autoclave cured and/or vacuum bagged). The mold may also be filled witha thermoplastic resin that is then “cured” in the sense that after theresin conforms to the shape of the mold, it is cooled until thethermoplastic resin is below its glass transition temperature andtherefore maintains its shape. Another method of producing carbon fibercomposites is by layering sheets of carbon fiber material that has beenpreimpregnated with thermoplastic resin or partially cured thermosettingresin (or has a layer of thermoplastic resin or partially curedthermosetting resin layered over each sheet) into a mold that is in theshape of the desired product. This assembly may then be placed in avacuum or is subject to thermal compression until the resin fully cures.

Despite the many benefits of carbon fiber composites, such compositesare typically black and the carbon fibers are typically visible on thecomposite surface. In addition, the fibers (either as a unidirectional,woven, or nonwoven substrate) are typically variable in theirconstruction and therefore are variable in their surface presentation.As a result, the resulting carbon fiber composite can have cosmeticimperfections that reduce the aesthetic appearance of the molded articleformed therefrom. Further, carbon fiber composites, often being black,provide a narrow range of surface appearance to the molded article andtherefore may give a “tired”, unexciting look.

BRIEF SUMMARY OF THE INVENTION

A composite laminate having an improved cosmetic surface is presentedherein. The composite laminate includes a plurality of sheets ofpreimpregnated material, or prepreg, stacked one over another and ascrim layer provided on an exterior surface of the sheets of prepreg.The scrim layer and the sheets of prepreg form a composite laminatewhereby the scrim layer constitutes an outer, exposed surface of thecomposite laminate. Each sheet of prepreg is made from fiberspreimpregnated with resin, and the fibers of the prepreg may besubstantially parallel or woven carbon fibers. The scrim layer may be aglass fiber or carbon fiber scrim, or veil, that has absorbed resin fromthe sheets of prepreg during a molding process. In another embodiment,the composite laminate includes a plurality of sheets of prepreg stackedone over another and first and second scrim layers provided on opposingexterior surfaces of the sheets of prepreg, whereby the sheets ofprepreg are sandwiched between the first and second scrim layers. Thefirst and second scrim layers constitute exposed surfaces of thecomposite laminate.

A method of making a composite laminate having an improved cosmeticsurface includes the steps of placing into a mold a scrim and aplurality of sheets of prepreg, with the scrim extending between thesheets of prepreg and an inner surface of the mold; forming a compositelaminate whereby the scrim is adhered to the sheets of prepreg; andremoving the composite laminate from the mold. An outer layer of thecomposite laminate includes the scrim. In one embodiment, the formingstep includes causing the scrim to absorb the resin from the sheets ofprepreg, whereby the resin and the scrim form the outer layer of thecomposite laminate.

Further embodiments, features, and advantages of the present inventions,as well as the structure and operation of the various embodiments of thepresent invention, are described in detail below, with reference to theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS/FIGURES

The accompanying drawings, which are incorporated herein and form partof the specification, illustrate the present invention and, togetherwith the description, further serve to explain the principles of theinvention and to enable a person skilled in the relevant art(s) to makeand use the invention. In the drawings, like reference numbers, letters,or renderings indicate identical or functionally similar elements.

FIG. 1A is a cross-sectional schematic view of a composite laminate forforming a molded article, in accordance with one embodiment of thepresent invention;

FIG. 1B is an enlarged view of a portion of the composite laminate ofFIG. 1A;

FIG. 2 is a exploded, schematic view of stacked sheets of resinimpregnated material and a scrim used to form the composite laminate ofFIG. 1A;

FIG. 3 is a cross-sectional schematic view of the material of FIG. 2placed in a mold for preparation of a molded article formed of thecomposite laminate of FIG. 1A, in accordance with one embodiment of thepresent invention; and

FIG. 4 is a cross-sectional schematic view of another composite laminatefor forming a molded article, in accordance with another embodiment ofthe present invention.

DETAILED DESCRIPTION OF THE INVENTION

A molded article in accordance with one embodiment of the presentinvention may be formed of a composite laminate 10, illustrated in FIGS.1A and 1B. Composite laminate 10 has opposing first and second surfaces12 and 14, respectively, and is formed of a composite 30 and a scrimlayer 20. Surface 12 is formed on the exterior of scrim layer 20.Surface 14 is formed on the exterior of composite 30. Composite 30 isformed of a plurality of sheets of prepreg 30 a-30 g that are fusedtogether during a molding process. An exemplary molding process formaking composite laminate 10 is provided below with reference to FIGS. 2and 3. In the embodiment illustrated in FIG. 1A, eight sheets of prepreg(30 a-30 g) form composite 30. However, it should be understood that anynumber of sheets of prepreg may be used. For example, in one embodiment,between 5 and 8 sheets may be used, and in another embodiment, 20 sheetsmay be used. Further, the sheets of prepreg can vary in thickness. Forexample, a sheet of prepreg can have a thickness in a range of about25-200 μm. Therefore, a designer may choose to use more or less sheetsof prepreg depending on the thicknesses of the sheets and the strengththe composite laminate that is desired.

As used herein, the term “prepreg” refers to fibers preimpregnated withresin, such as a combination of a fibrous substrate (such as a mat,fiber, or cloth material) with resin impregnated on and into thesubstrate. Each sheet of prepreg 30 a, b, . . . g is a substantiallyplanar sheet of fibers impregnated with a resin that is initially readyfor curing. During the molding process for forming composite laminate10, the resin of prepreg sheets 30 a-30 g are cured. There are manytypes of resins that may be used in prepreg sheets 30 a-30 g, including,but not limited to, conventional thermoplastic resins and conventionalthermosetting resins such as epoxies. The resin is typically at anintermediate stage prior to becoming fully cured. The fibers of theprepreg sheets 30 a-30 g sheets may be, for example, carbon fibers. Toproduce a sheet of prepreg, continuous fibers formed from bundles offilaments may be linearly oriented to produce a sheet of unidirectionalfibers, or the fibers may be woven to produce a woven sheet, as known toone of skill in the relevant art(s). These fibrous sheets are thenimpregnated with resin to form sheets of prepreg. Sheets of prepreg 30a-30 g can be formed using conventional methods for impregnating fiberswith resin. For example, one method of manufacturing a sheet of prepregis disclosed in U.S. Pat. No. 5,201,979, which is incorporated herein inits entirety by reference thereto.

As shown in FIG. 1B, scrim layer 20 is formed of a scrim 22 and resin23. During the molding process, excess resin 23 from the plurality ofsheets of prepreg 30 a-30 g seeps through and is absorbed by scrim 22,such that surface 14 of composite laminate 10 includes resin 23 andscrim 22. Scrim 22 is thin (e.g., about 50 μm thickness), and may bemade of a nonwoven mat of fibers, randomly oriented, similar to felt.The fibers of scrim 22 may be carbon fibers, glass fibers, and syntheticresin fibers (e.g., aramid fiber). The fibers may also be inorganicfibers such as metal fibers (e.g., aluminum fibers or titanium fibers).In one embodiment, scrim 22 may be a nonwoven glass fiber scrim, and inanother embodiment scrim 22 may be a nonwoven carbon fiber scrim, suchas Part #1064 produced by Fibre Glast Developments Corp. of Brookville,Ohio. Also, in one embodiment, scrim 22 may be impregnated with resin.

Since glass fiber is less stiff than carbon fiber, composite laminate 10having a glass fiber scrim has improved impact resistance over a likecomposite laminate incorporating a carbon fiber scrim. Scrim 22 extendsover composite 30 and hides the reinforcing fibers of prepreg sheets 30a-30 g. Since scrim 22 absorbs resin 23 of the composite 30, scrim 22takes on the cosmetic properties and color of resin 23. Also, as notedabove, scrim 22 is very thin, and it is translucent, and the underlyingfibers of composite 30 are partially visible therethrough. Thecombination of resin 23 and scrim 22 forming scrim layer 20 imparts adepth to surface 12 of composite laminate 10, thereby providing animproved cosmetic surface of a molded article formed therefrom that isnot only consistent in appearance, but is also aesthetically pleasing.

Resin 23 may be clear or pigmented. Clear resin would provide the mostvisibility of scrim 22 and the underlying fibers of composite 30, andtherefore provides a greater perception of depth to surface 12 thanpigmented resin. For example, pigmented resin would produce atranslucent, colored surface, altering the apparent depth of surface 12of composite laminate 10 and providing further variation to the cosmeticsurface of the molded article. Moreover, if a clear glass fiber scrim isused as part of scrim layer 20, scrim 22 would be transparent, such thatpigmented resin has a greater impact on the color and apparent depth ofsurface 12 of composite laminate 10. To provide further variation to theappearance of surface 12, the thickness of the scrim may be varied. Inone embodiment, the scrim may be just thick enough to be substantiallyopaque, whereby the underlying fibers of prepreg sheets 30 a-30 g arenot visible therethrough.

Composite laminate 10 may be provided with a smooth and/or texturedsurface. A textured surface may be achieved by applying a texture to theinner surface of a mold, which is then transferred to resin 23 duringthe molding process. As such, the several embodiments of the presentinvention described herein provide a designer with the opportunity toproduce molded articles that have the advantageous properties of carbonfiber composites, without being limited to its black color or itsimperfections in appearance. Composite laminate 10 may form any shape ofmolded article. In one embodiment, the molded article is an enclosure,such as a housing for an electronic device, with first surface 12 beingthe outer, exposed surface of the molded article, and second surface 14constituting an inner, hidden surface thereof. In this instance, scrimlayer 20 imparts the enclosure with a consistent and pleasing cosmeticsurface. Further, in molded articles having irregular curved portions,such as curved corners of an enclosure, the underlying fibers of theprepreg sheets are most likely to be inconsistently oriented and aretherefore less likely to provide the molded article with a uniformappearance. Therefore, the presence of scrim layer 20 providescongruency between the appearance of the irregular curved portions ofthe enclosure.

A method of making composite laminate 10 will now be described withreference to FIGS. 2 and 3. FIG. 2 shows an exploded, schematic view ofa plurality of sheets of prepreg 30 a-30 g and a scrim 22, prior tobeing laminated together to form composite laminate 10 shown in FIG. 1A.In the schematic of FIG. 2, each sheet of prepreg 30 a, b . . . g, maybe formed of woven, nonwoven or parallel (i.e., unidirectional) fibers.In one embodiment, the fibers of at least one sheet of prepreg may besubstantially woven. In another embodiment, the fibers of at least onesheet of prepreg of composite 30 may be substantially parallel carbonfibers. In another embodiment, all sheets of prepreg that form composite30 may be formed of substantially parallel carbon fibers. Further, inone embodiment, fibers of adjacent sheets 30 a, b . . . g may bedisposed at an angle to one another, such as illustrated in FIG. 2.Typically, the orientation of the fibers of the adjacent sheets ofprepreg are varied to improve the strength of the molded article formedtherefrom.

Extending over a face of composite 30 is a scrim 22. In the embodimentof FIG. 2, scrim 22 extends beneath prepreg sheet 30 a, and scrim 22 andsheets 30 a-30 g form an assembly 40 that may then be placed in a moldall at once. FIG. 3 shows assembly 40 placed in a mold 50 such thatscrim 22 extends between an inner surface of mold 50 and the bottom-mostprepreg sheet (i.e., sheet 30 a) of composite 30, with prepreg sheets 30a-30 g stacked over scrim 22. Alternatively, assembly 40 may be formeddirectly in mold 50 by placing scrim 22 in mold 50 and thereafterplacing individual prepreg sheets 30 a, b . . . g in mold 50.

Scrim 22 is then adhered to composite 30 during a molding processconventional in the relevant art, for example, by applying heat and/orpressure so as to laminate together scrim 22 and prepreg sheets 30 a-30g and cure resin 23. When assembly 40 is laminated together to formcomposite laminate 10, scrim 22 absorbs excess resin 23 of prepregsheets 30 a-30 g, thereby forming scrim layer 20 which is unitary withcomposite 30, as illustrated in FIGS. 1A and 1B. Thereafter, thelaminated prepreg sheets 30 a-30 g and scrim layer 20 are removed frommold 50, with scrim layer 20 forming surface 12 of composite laminate10.

In another embodiment, depicted in FIG. 4, a composite laminate 60 maybe formed in which the plurality of prepreg sheets 30 a-30 g ofcomposite 30 are sandwiched between scrim layer 20 and a second scrimlayer 80, which constitute an outer surface 62 and an inner surface 64,respectively, of composite laminate 60. As such, both inner and outersurfaces of a molded article formed from composite laminate 60 areprovided with a consistent, aesthetically pleasing appearance, which maybe especially desired when both the inner and outer surfaces of themolded article are visible to a user.

Composite laminate 60 may be formed similar to composite laminate 10,but with assembly 40 of FIG. 3 including another scrim extending overthe upper-most prepreg sheet (i.e., sheet 30 g) of composite 30. Duringa compression molding process, excess resin from prepreg sheets 30 a-30g would also seep through the scrim over prepreg sheet 30 g, adheringthe scrim to composite 30. The resin and scrim forms scrim layer 80. Thescrims of scrim layers 20 and 80 may be formed of like materials (e.g.,both scrims are carbon fiber scrims), or the scrims may be formed ofdifferent materials (e.g., scrim 22 may be a glass fiber scrim while thescrim of scrim layer 80 is a carbon fiber scrim). It should therefore beapparent that various modifications to scrim layers 20 and/or 80 ofcomposite laminate 60 may be employed so as to achieve molded articleshaving a variety of cosmetic surfaces in accordance with the presentinvention.

While various embodiments of the present invention have been describedabove, it should be understood that they have been presented by way ofexample only, and not limitation. It will be apparent to persons skilledin the relevant art that various changes in form and detail can be madetherein without departing from the spirit and scope of the invention.Thus, the breadth and scope of the present invention should not belimited by any of the above-described exemplary embodiments, but shouldbe defined only in accordance with the following claims and theirequivalents.

What is claimed is:
 1. A method of making a composite laminate,comprising: placing into a mold a scrim and a plurality of sheets ofprepreg, each sheet of prepreg including fibers preimpregnated withresin, wherein the scrim extends between an exterior surface of theplurality of sheets of prepreg and an inner surface of the mold,wherein: the scrim is made of a nonwoven mat of randomly orientedfibers, the fibers of each sheet of prepreg are substantially parallelcarbon fibers, and the carbon fibers in adjacent sheets of prepreg aredisposed at an angle relative to one another; forming a compositelaminate whereby the scrim is adhered to the sheets of prepreg and thefibers of at least one sheet of the plurality of sheets of prepreg areat least partially visible through the scrim; and removing the compositelaminate from the mold, wherein an outer layer of the composite laminateincludes the scrim and forms an outer, exposed surface of the compositelaminate.
 2. The method of claim 1, wherein the step of forming thecomposite laminate causes the scrim to absorb resin from the sheets ofprepreg, whereby the resin and scrim constitute the outer layer of thecomposite laminate.
 3. The method of claim 1, wherein the fibers of thescrim are carbon fibers.
 4. The method of claim 1, wherein the step ofplacing the scrim and the plurality of sheets of prepreg into the moldcomprises: placing the scrim into the mold; and placing the sheets ofprepreg into the mold over the scrim after the scrim has been placedinto the mold.
 5. The method of claim 1, wherein the step of forming thecomposite laminate includes subjecting the scrim and the sheets ofprepreg to heat and pressure.
 6. The method of claim 1, furthercomprising: placing a second scrim into the mold so that the sheets ofprepreg are disposed between the first scrim and the second scrim,wherein the step of forming the composite laminate includes causing thesecond scrim to absorb the resin from the sheets of prepreg, whereby theresin and the scrim form a second outer layer of the composite laminate,the sheets of prepreg being sandwiched between the first and secondouter layers.
 7. The method of claim 6, wherein at least one of thefirst and second scrims is formed of carbon fibers.
 8. The method ofclaim 6, wherein at least one of the first and second scrims is formedof glass fibers.
 9. The method of claim 6, wherein the resin in eachsheet of prepreg is pigmented.
 10. The method of claim 6, wherein atleast one of the first and second scrims is formed of carbon fibers andanother is formed of glass fibers.
 11. The method of claim 1, whereinthe outer, exposed surface of the composite laminate is textured,wherein an inner surface of the mold has a texture which is transferredto the resin during forming of the composite laminate.
 12. A method ofmaking a composite laminate, comprising: placing a first scrim into amold, wherein the first scrim is made of a nonwoven mat of randomlyoriented fibers; and placing a plurality of sheets of prepreg over thefirst scrim in the mold, each sheet of prepreg including fiberspreimpregnated with resin, wherein: the first scrim extends between anexterior surface of the plurality of sheets of prepreg and an innersurface of the mold, the fibers of each sheet of prepreg aresubstantially parallel carbon fibers, and the carbon fibers in adjacentsheets of prepreg are disposed at an angle relative to one another;placing a second scrim into the mold so that the sheets of prepreg aredisposed between the first scrim and the second scrim; forming acomposite laminate by causing the first and second scrims to absorb theresin from the sheets of prepreg whereby the first and second scrims areadhered to the sheets of prepreg and the fibers of at least one sheet ofthe plurality of sheets of prepreg are at least partially visiblethrough at least one of the first scrim or the second scrim; andremoving the composite laminate from the mold, wherein the resin and thefirst scrim constitute a first outer layer that forms an outer, exposedsurface of the composite laminate, and wherein the resin and the secondscrim form a second outer layer of the composite laminate, the sheets ofprepreg being sandwiched between the first and second outer layers. 13.The method of claim 12, wherein at least one of the first and secondscrims is formed of carbon fibers or glass fibers.
 14. The method ofclaim 12, wherein one of the first or second scrims is formed of carbonfibers and the other of the second or first scrims is formed of glassfibers.
 15. The method of claim 12, wherein the resin in the sheets ofprepreg is pigmented.
 16. The method of claim 12, wherein the outer,exposed surface of the composite laminate is textured, wherein an innersurface of the mold has a texture which is transferred to the resinduring forming of the composite laminate.
 17. The method of claim 12,wherein the fibers of each sheet of prepreg are nonwoven.